Unequal length alternating hydraulic cylinder drive system for continuous material output flow with equal material output pressure

ABSTRACT

A hydraulic pumping system is provided for delivering a compressible fluid material from a hopper to an outlet. A primary hydraulically driven pumping unit has a first interior volume for receiving the fluid material from the hopper. A secondary hydraulically driven pumping unit is interconnected with the primary hydraulically driven pumping unit and has a second interior volume less than the first interior volume for receiving fluid material from the primary hydraulically driven pumping unit. The primary and secondary hydraulically driven pumping units have hydraulically driven reciprocating piston units with unequal stroke lengths. The piston units are alternately reciprocated to fill the first interior volume of fluid material from the hopper, pump a portion of the first interior volume of fluid material into the second interior volume and the remainder of the first interior volume to the outlet, and pump the second interior volume of fluid material to the outlet while fluid material is being pulled into the first interior volume in a sequential and simultaneous manner which will produce substantially continuous delivery of fluid material to the outlet.

FIELD OF THE INVENTION

The present invention relates generally to the field of pumps, and more particularly, pertains to a positive displacement pump arrangement designed to produce substantially continuous delivery of a compressible fluid material.

BACKGROUND OF THE INVENTION

Constant delivery fluid pumps find useful application in many fields. One field in which the pumps of this character are presently employed to advantage is the construction industry wherein it is relatively common practice to apply cement and plaster to building surfaces by means of spray nozzles. If a relatively uniform layer of plaster or cement material is to be applied to a building surface, the rate of flow of material from the spray nozzle of the spray unit must be relatively constant. This, in turn, requires a constant delivery pump capable of producing substantially a constant rate of material flow to the spray nozzle.

Prior art pumps are, of course, known in the art, and are generally comprised of a pair of pumping units actuated in such a manner that the pumping discharges from the pumping units overlap in a manner to produce a substantially constant flow delivery at an outlet. Valve members are typically provided so that one pumping unit serves as a primary unit to initially discharge pumped material concurrently into a delivery line and into a cylinder of the other pumping unit which then operates as a secondary pumping unit to discharge its previously received material into the delivery line.

One such prior art arrangement is embodied in a pair of equal stroke length material cylinders alternately driven by equal stroke length hydraulic cylinders. This arrangement requires either four separate ball and seat valves or the switching of a tube, commonly referred to as an S-tube, that changes between the material cylinders.

Another prior art arrangement is formed by a pair of unequal stroke length material cylinders driven by a mechanical pumping assembly, in which the pumping action of the primary and secondary pumping units is effected mechanically by the interaction of a crank arm and a cam with follower. The mechanical pumping assembly can be variously driven by an engine or electric motor via a clutch, belts or chains, pulleys or sprockets, and a gearbox, all of which is undesirably complex. This design requires an external mechanical pressure limiting device. In addition, the pumping output rate is sometimes limited to preset pulley or sprocket ratios. The mechanical pumping assembly can also be variously driven by an engine or electric motor via a hydraulic pump and motor combination, but this retains the complexity and the high number of wearing components inherent to the mechanical pumping assembly.

Accordingly, the present invention is concerned more particularly with a new and improved design of pumping apparatus in which the inherent draw backs of the prior art have been overcome. There is a need for a hydraulic equivalent to the prior art mechanical system wherein the unequal stroke length of the two material cylinders reduces the number of and simplifies components required for the pumping system, while allowing the material pressure to be equalized by controlling the pressure of the hydraulic fluid and the appropriate size combination of hydraulic cylinders.

SUMMARY OF THE INVENTION

It is a general object of the present invention to provide a positive displacement pump in which operatively associated pumping units are interconnected hydraulically for alternating operation such that a substantially constant flow of material will be produced at an outlet.

It is also an object of the present invention to provide a constant delivery hydraulically driven pump having primary and secondary piston/cylinder units with unequal stroke lengths, and a pair of valve members for controlling the supply of material into the pumping units and into a delivery outlet.

It is another object of the present invention to provide a hydraulically driven pumping system having unequal stroke length material cylinders with equal material output pressure.

It is a further object of the present invention to provide a pump apparatus which is especially suited to the pumping of cement, plastic and other abrasive materials.

It is an additional object of the present invention to provide a hydraulically driven pumping arrangement for abrasive materials which offers improved performance, reliability and cost in installation and service.

The present invention relates to a hydraulically driven pumping system for delivering a compressible fluid material from a hopper to an outlet. The system includes a primary hydraulically driven pumping unit having a first interior volume for receiving the fluid material from the hopper. A secondary hydraulically driven pumping unit is interconnected with the primary pumping unit and has a second interior volume less than the first interior volume for receiving fluid material from the primary hydraulically driven pumping unit. The primary and secondary hydraulically driven pumping units have hydraulically driven reciprocating piston units with unequal stroke lengths. The piston units are alternately reciprocated to fill the first interior volume with fluid material from the hopper, pump a portion of the first interior volume of fluid material into the second interior volume and the remainder of the first interior volume to the outlet, and pump the second interior volume of fluid material to the outlet while fluid material is being pulled into the first interior volume in a simultaneous and sequential manner which will produce substantially continuous delivery of fluid material to the outlet.

In the preferred embodiment, the piston units are reciprocated in primary and secondary hydraulic cylinders of unequal lengths. The piston units are reciprocated in primary and secondary material cylinders of unequal lengths that have substantially equal output pressures. A single ball and seat combination, functioning as a check valve is positioned between the hopper and the primary hydraulically driven pumping unit. An additional single ball and seat combination functioning as a check valve is positioned between the primary hydraulically driven pumping unit and the secondary hydraulically driven pumping unit.

In another aspect of the invention, a hydraulically driven pumping system for delivering a compressible fluid material from a hopper to an outlet includes a primary pumping unit having a primary material cylinder with a first interior volume for receiving the fluid material from the hopper, a primary hydraulic cylinder fed by a source of hydraulic fluid, and a primary piston unit movable back and forth over a stroke length within the primary material cylinder and the primary hydraulic cylinder. A secondary pumping unit has a secondary material cylinder having a second interior volume less than the first interior volume for receiving the fluid material from the primary material cylinder, a secondary hydraulic cylinder sized smaller than the primary hydraulic cylinder and fed by the source of hydraulic fluid, and a secondary piston unit movable back and forth over a stroke length within the secondary material cylinder and the secondary hydraulic cylinder. The stroke length of the secondary piston unit is less than the stroke length of the primary piston unit. A first ball and seat combination functioning as a check valve is located between the hopper and the primary material cylinder. A second ball and seat combination functioning as a check valve is located between the primary material cylinder and the secondary material cylinder. The primary and secondary piston units are hydraulically controlled and alternately reciprocated over their respective unequal stroke lengths to fill the first interior volume with fluid material from the hopper, pump a portion of the first interior volume of fluid material into the second interior volume and the remainder to the outlet, and pump the second interior volume of fluid material to the outlet while the fluid material is being pulled into the first interior volume in a simultaneous and sequential manner which will produce substantially continuous delivery of fluid material to the outlet.

The lengths of the primary and secondary material cylinders are unequal, and the lengths of the primary and secondary hydraulic cylinders are unequal. Each of the primary and secondary piston units include a material piston adapter and a hydraulic cylinder rod having pistons on opposite ends thereof. The primary and secondary piston units have unequal hydraulic cylinder rod diameters. The hydraulic cylinder rod of the primary piston unit has a diameter that is greater than the diameter of the hydraulic cylinder rod of the secondary piston unit. The primary and secondary material cylinders have outlet pressures that are equalized by appropriately sizing the primary and second material cylinders with equal bore diameters, sizing the primary and second hydraulic cylinders with equal piston diameters and driving the primary and secondary piston units alternately by the same hydraulic pump. Sensors are included within the primary and secondary pumping units for detecting the position of the primary and secondary piston units. The primary and secondary hydraulic cylinders are hydraulically connected to each other and to a source of secondary hydraulic pump pressure. A material output rate is infinitely variable by controlling the hydraulic fluid supply to the primary and secondary hydraulic cylinders. The primary and secondary piston units have equal extension speed, but have unequal retraction speed. The volume of the primary material cylinder is substantially twice the volume of the secondary material cylinder.

The invention also contemplates a method of delivering a substantially constant flow of fluid material from a hopper to an outlet using a hydraulic pumping system. The method comprises the step of

(a) providing a primary hydraulically driven pumping unit having a first interior volume for receiving the fluid material from the hopper;

(b) providing a secondary hydraulically driven pumping unit interconnected with the primary hydraulically driven pumping unit and having a second interior volume less than the first interior volume for receiving fluid material from the primary hydraulically driven pumping unit;

(c) providing the primary and secondary hydraulically driven pumping units with hydraulically driven reciprocating piston units with unequal stroke lengths; and

(d) alternately reciprocating the piston units to fill the first interior volume with fluid material from the hopper, pump a portion of the first interior volume of fluid material into the second interior volume and the remainder of the first interior volume to the outlet, and pump the second interior volume of fluid material to the outlet while fluid material is being pulled into the first interior volume in a sequential and simultaneous manner which will produce a substantially continuous delivery of fluid material to the outlet.

Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate the best mode presently contemplated for carrying out the invention.

In the drawings:

FIGS. 1 and 2 are schematic illustrations of an unequal length hydraulic cylinder drive system embodying the present invention and showing alternating phases of operation.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, a hydraulic cylinder drive system 10 forms a constant delivery pump used to provide a pressurized supply of abrasive, compressible fluid material, typically cement, plaster, mortar or the like, from a reservoir or hopper 12 to an outlet 14. Material delivered to the outlet 14 is normally directed to a spray nozzle for distribution to a desired surface, such as a building wall.

The system 10 includes a primary hydraulically driven pumping unit defined by a primary material cylinder 16 have a feed line 18 in communication within hopper 12 and an interior volume A at a head of the cylinder 16. A first one-way check valve 20 is positioned in feed line 18 between hopper 12 and primary material cylinder 16. The check valve 20 is a conventional mechanical design having a ball 22 movable between a stop 24 and a seat 26. The check valve 20 allows flow of material from hopper 12 into material cylinder 16 through the line 18, but blocks flow in the reverse direction.

A primary piston unit 28 has a material piston adapter 30 with a material piston 32 movable within the interior of primary material cylinder 16, and a hydraulic cylinder rod 34 with a second piston 36 opposite material piston 32 that is movable within an interior of primary hydraulic cylinder 38. As will be appreciated, piston adapter 30, hydraulic cylinder rod 34, and pistons 32, 36 move back and forth in sealed relationship within primary material cylinder 16 and primary hydraulic cylinder 38. Primary piston unit 28 has a particular stroke length as determined by the lengths of primary material cylinder 16 and primary hydraulic cylinder 38. One end of primary hydraulic cylinder 38 is provided with a hydraulic line 40 connected to a primary hydraulic pump for supplying and returning hydraulic fluid relative to a source. Flow of hydraulic fluid through feed line 40 is separately controlled.

The system 10 further includes a secondary hydraulically driven pumping unit defined by a secondary material cylinder 42 having a feed line 44 in communication with an interior volume B at a head of cylinder 42. The feed line 44 is further in communication with the line 18 extending from the primary material cylinder 16. A second one-way check valve 46 is positioned in line 44 between primary material cylinder 16 and the secondary material cylinder 42. The check valve 46 is a conventional design like check valve 20 having a ball 48 movable between a stop 50 and a seat 52. The check valve 46 allows flow from line 18 into line 44, the secondary material cylinder 42 and outlet 14, but prevents flow back into line 18.

It is important to note that secondary material cylinder 42 has a length that is shorter than the length of primary material cylinder 16, and that interior volume B of secondary material cylinder 42 is less than interior volume A of primary material cylinder 16. Interior diameters of the material cylinders 16 and 42 are substantially equal.

A secondary piston unit 54 has a material piston adapter 56 with a material piston 58 movable within the interior of secondary material cylinder 42, and a hydraulic cylinder rod 60 with a hydraulic cylinder piston 62 opposite material piston 58 that is movable within an interior of a secondary hydraulic cylinder 64. Piston adapter 56, hydraulic cylinder rod 60 and pistons 58, 62 move back and forth in sealed relationship within secondary material cylinder 42 and secondary hydraulic cylinder 64. Secondary piston unit 54 has a particular stroke length as determined by the length of secondary hydraulic cylinder 64. It is a key feature of the invention that the stroke length of secondary piston unit 54 is less than the stroke length of primary piston unit 28.

Secondary hydraulic cylinder 64 has a length which is shorter than the length of primary hydraulic cylinder 38, and an interior volume which is less than the interior volume of primary hydraulic cylinder 38. Diameters of the hydraulic cylinder pistons 36, 62 are substantially equal.

One end of secondary hydraulic cylinder 64 is provided with a hydraulic line 66 connected to a primary hydraulic pump for supplying and returning hydraulic fluid relative to the source. A rod side of secondary hydraulic cylinder 64 is hydraulically connected with a rod side end of primary hydraulic cylinder 38 by means of a common line 68. A further hydraulic line 70 is connected to line 68 and to a secondary hydraulic pump for supplying and returning hydraulic fluid relative to the rod side of hydraulic cylinders 38, 64. Proximity sensors 72 a, 74 a are positioned adjacent the material cylinders 16, 42 to detect the fully extended position of piston units 28, 54 therein and signal a change in direction for both piston units. Alternatively, proximity sensors 72 b, 74 b are positioned adjacent the hydraulic cylinders 38, 64 to detect the fully extended position of piston units 28,54 therein and signal a change in direction for both piston units. Detection of piston location and signaling direction change may be done by a means other than a proximity sensor, whether electrical, mechanical or hydraulic in nature.

It is another key feature of the present invention that the diameter of the hydraulic cylinder rod 34 in primary hydraulic cylinder 38 is greater than the diameter of the hydraulic cylinder rod 60 of the secondary hydraulic cylinder 64 as will be fully appreciated below.

Operation of the system 10 as described above is as follows referring first to FIG. 1. Material to be pumped is placed in the hopper 12. A primary hydraulic pump is connected to the piston side of hydraulic cylinder 64 via line 66 causing secondary piston unit 54 to extend. The hydraulic connection 68 from the rod side of hydraulic cylinder 64 to the rod side of hydraulic cylinder 38 causes primary piston unit 28 to retract. The retraction of piston unit 28 causes material to be drawn into primary material cylinder 16 from the hopper 12 past ball 22 and seat 26 and through line 18. At the full extension of piston unit 54, the proximity sensor 74 a or 74 b signals a change in direction for stroking the piston units 28, 54.

Referring now to FIG. 2, the primary hydraulic pump flow changes from being directed to the piston side of hydraulic cylinder 64 to the piston side of hydraulic cylinder 38. Piston unit 28 extends causing approximately half the material within material cylinder 16 to be pumped out of the outlet 14, while the other half is pumped into material cylinder 42 as piston unit 54 is retracted. Retraction is caused due to the common line 68 from the rod side of hydraulic cylinder 38 to the rod side of hydraulic cylinder 64. Retraction is further assisted by the action of pumping material from material cylinder 16 to material cylinder 42. The retraction of piston unit 54 causes material to be drawn into material cylinder 42 from material cylinder 16 past the ball 48 and seat 52 and through line 44. At the full extension of piston unit 28, the proximity sensor 72 a or 72 b signals the change in direction for the piston units 28, 54. The primary hydraulic pump flow changes from being directed to the piston side of hydraulic cylinder 38 to the piston side of hydraulic cylinder 64. Piston unit 54 extends causing its full volume of material in material cylinder 42 to be pumped out the outlet 14. Material is prevented from back flowing into line 18 by check valve 46. The piston unit 28 is simultaneously retracted. The above steps are repeated to provide a substantially continuous flow of material to the outlet 14.

During operation, piston units 28, 54 fully extend and retract on each alternating stroke with piston unit 28 having a longer stroke length than the piston unit 54. The common line 68 establishes a master-slave relationship and allows for transfer of fluid between the hydraulic cylinders 38, 64 upon reciprocation of piston units 28, 54. When pumping from material cylinder 16, approximately one-half the volume is pumped into material cylinder 42 and the other half is pumped out to outlet 14. When pumping from material cylinder 42, its full volume is pumped out the outlet 14.

Piston units 28, 54 have an equal extension speed. Hydraulic cylinders 38, 64 have equal diameter pistons 36, 62. The piston units 28, 54 are alternately driven by the same primary hydraulic pump. However, piston units 28, 54 have an unequal retraction speed. Each piston unit 28 or 54 must reach the fully retracted position at approximately the same time or before the other piston unit 28 or 54 is fully extended. The longer stroke piston unit 28 retracts at a faster speed than the piston unit 54 extends. Piston unit 54 retracts at a slower speed than piston unit 28 extends. This is accomplished by the rods 34, 60 having unequal rod diameters such that that the diameter of rod 34 is greater than the diameter of rod 60. This is further accomplished by making the hydraulic cylinders 38, 64 with equal rod-side volumes. Retraction speed of the secondary piston unit 54 may be increased with the addition of material pressure being pumped from the primary piston unit 28.

The piston units 28, 54 fully extend and fully retract on each alternate stroke due to the proximity sensors 72 a, 72 b, 74 a, 74 b which signal the change of direction of the stroking for piston units 28, 54 upon their full extension. The secondary hydraulic pump supplies additional hydraulic oil between hydraulic cylinders 38, 64 via lines 68, 70 to ensure full retraction of piston units 28, 54 occurs before the change of signal is actuated.

Material output rate is infinitely variable by controlling the primary pump flow delivered to hydraulic cylinders 38, 64. Material is pumped at equal material pressure from both material cylinders 16, 42 due to the fact that material cylinders 16, 42 have equal bore diameters, hydraulic cylinders 38, 64 have equal diameter pistons 36, 62 and the hydraulic cylinders 38, 64 are driven at the piston side by the same primary hydraulic pump. Maximum material pressure is accurately limited by a corresponding maximum hydraulic pressure setting at the primary hydraulic pump.

The present invention thus provides a positive displacement hydraulic cylinder drive system wherein a partial volume A and volume B of material are pumped on each alternating, unequal length stroke of coordinating piston units 28, 54 to continuously pump material to the outlet 14. In contrast with the prior art, the system 10 reduces the number of components required (minimizing the number of check valves), eliminates the need for complex drive systems and separate mechanical pressure limiting devices as encountered in mechanical systems, and allows a greater control of the maximum pressure of the material cylinders.

It should be understood that the hydraulic system 10 can be either an open loop or a closed loop system. For the purpose of detecting and signaling change of direction of the piston units, the type, the amount and/or location of the proximity sensor may vary. Also, the change in direction could be detected alternately using hydraulic pressure signals and correspondingly piloted valves.

Various alternatives and embodiments are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter regarded as the invention. 

1. A hydraulically driven pumping system for delivering a compressible fluid material from a hopper to an outlet, the system comprising: a primary hydraulically driven pumping unit having a first interior volume for receiving the fluid material from the hopper; and a secondary hydraulically driven pumping unit interconnected with the primary hydraulically driven pumping unit and having a second interior volume less than the first interior volume for receiving fluid material from the primary hydraulically driven pumping unit, the primary and secondary hydraulically driven pumping units having hydraulically driven reciprocating piston units with unequal stroke lengths, the piston units being alternately reciprocated to fill the first interior volume with fluid material from the hopper, pump a portion of the first interior volume of fluid material into the second interior volume and the remainder of the first interior volume to the outlet, and pump the second interior volume of fluid material to the outlet while fluid material is being pulled into the first interior volume in a simultaneous and sequential manner which will produce substantially continuous delivery of fluid material to the outlet.
 2. The pumping system of claim 1, wherein the piston units are reciprocated in primary and secondary hydraulic cylinders having equal bores, unequal lengths, and pistons with equal diameters.
 3. The pumping system of claim 1, wherein the piston units are reciprocated in primary and secondary material cylinders having equal bores, unequal lengths that have substantially equal output pressures, and pistons with equal diameters.
 4. The pumping system of claim 1, wherein a single check valve is positioned between the hopper and the primary pumping unit.
 5. The pumping system of claim 4, wherein a single check valve is positioned between the primary pumping unit and the secondary pumping unit.
 6. A hydraulically driven pumping system for delivering a compressible fluid material from a hopper to an outlet, the system comprising: a primary hydraulically driven pumping unit having a primary material cylinder having a piston, a bore and a first interior volume for receiving the fluid material from the hopper, a primary hydraulic cylinder provided with a piston, and a bore and fed by a source of hydraulic fluid and a primary piston unit movable back and forth over a stroke length within the primary material cylinder and the primary hydraulic cylinder; a secondary hydraulically driven pumping unit having a secondary material cylinder having a piston, a bore and a second interior volume less than the first interior volume for receiving the fluid material from the primary material cylinder, a secondary hydraulic cylinder provided with a piston and a bore and sized smaller than the primary hydraulic cylinder and fed by the source of hydraulic fluid, and a secondary piston unit movable back and forth over a stroke length within the secondary material cylinder and the secondary hydraulic cylinder, a stroke length of the secondary piston unit being less than the stroke length of the primary piston unit; a first check valve located between the hopper and the primary material cylinder; and a second check valve located between the primary material cylinder and the secondary material cylinder, wherein the primary and secondary piston units are hydraulically controlled and alternately reciprocated over their respective unequal stroke lengths to fill the first interior volume with fluid material from the hopper, pump a portion of the first material volume of first interior volume of fluid material into the second interior volume and the remainder to the outlet, and pump the second interior volume of fluid material to the outlet while the fluid material is being pulled into the first interior volume in a sequential and simultaneous manner which will produce substantially continuous delivery of fluid material to the outlet.
 7. The pumping system of claim 6, wherein the primary and second material cylinders have equal bore and piston diameters and unequal lengths.
 8. The pumping system of claim 6, wherein the primary and secondary hydraulic cylinders have equal bore and piston diameters and unequal lengths.
 9. The pumping system of claim 6, wherein each of the primary and secondary piston units include material piston adapters and hydraulic cylinder rods.
 10. The pumping system of claim 9, wherein the hydraulic cylinder rods of the primary and secondary piston units have unequal diameters and lengths.
 11. The pumping system of claim 9, wherein the hydraulic cylinder rod of the primary piston unit has a diameter that is greater than a diameter of the hydraulic cylinder rod of the secondary piston unit.
 12. The pumping system of claim 6, wherein the primary and secondary material cylinders have outlet pressures that are equalized by appropriately sizing the primary and secondary material cylinders with equal bore and piston diameters, sizing the primary and secondary hydraulic cylinders with equal bore and piston diameters, and driving the primary and secondary piston units alternately by the same hydraulic pump.
 13. The pumping system of claim 6, wherein proximity sensors are included within the primary and secondary pumping units for detecting a fully extended position of the primary and secondary piston units.
 14. The pumping system of claim 6, wherein the primary and secondary hydraulic cylinders are hydraulically connected to each other and to a source of secondary hydraulic pump pressure.
 15. The pumping system of claim 6, wherein the material output rate is infinitely variable by controlling the hydraulic fluid supplied to the primary and secondary hydraulic cylinders.
 16. The pumping system of claim 6, wherein the primary and secondary piston units have equal extension speed.
 17. The pumping system of claim 6, wherein the primary and secondary piston units have unequal retraction speed.
 18. The pumping system of claim 6, wherein the volume of the primary material cylinder is substantially twice the volume of the secondary material cylinder.
 19. A method of delivering a substantially constant flow of fluid material from a hopper to an outlet using a hydraulically driven pumping system, the method comprising the steps of: a) providing a primary hydraulically driven pumping unit having a first interior volume for receiving the fluid material from the hopper; b) providing a secondary hydraulically driven pumping unit interconnected with the primary hydraulically driven pumping unit and having a second interior volume less than the first interior volume for receiving fluid material from the primary hydraulically driven pumping unit; c) providing the primary and secondary hydraulically driven pumping units with hydraulically driven reciprocating piston units with unequal stroke lengths; and d) alternately reciprocating the piston units to fill the first interior volume with fluid material from the hopper, pump a portion of the first interior volume of fluid material into the second interior volume and the remainder of the first interior volume to the outlet, and pump the second interior volume of fluid material to the outlet while the fluid material is being pulled into the first interior volume in a sequential and simultaneous manner which will produce substantially continuous delivery of fluid material to the outlet. 